Solid air freshener

ABSTRACT

The present invention relates to a solid pressed air freshener and odor neutralizer composition which can include greater than 10% fragrance. The air freshener comprises a fragrance; preferably the fragrance is impregnated within a water soluble substrate made from a foamed vegetable starch, a surfactant and a solidifier. The solid formulations break down easily in the presence of water and may be sprayed, within the area to be freshened.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a Continuation Application of U.S. Ser. No. 15/221,351 filedJul. 27, 2016, which is a Continuation Application of U.S. Ser. No.14/564,663 filed Dec. 9, 2014, now U.S. Pat. No. 9,402,930, which is aContinuation Application of abandoned U.S. Ser. No. 13,302,570 filedNov. 22, 2011. The entire contents of this patent application are herebyexpressly incorporated herein by reference including, withoutlimitation, the specification, claims, and abstract, as well as anyfigures, tables, or drawings thereof.

FIELD OF THE INVENTION

This invention relates to air fresheners and deodorizers and, inparticular, this invention relates to water soluble air fresheners androom deodorizers in concentrated solid pressed formulations that arediluted on site by the customer to yield a liquid composition for use indomestic, institutional and/or industrial applications.

BACKGROUND OF THE INVENTION

Various types of air fresheners have been made to dispense fragrancesand scents to mask or neutralize unpleasant odors or to simply provide apleasant scent in a volume of air. One type of air freshener involvesdissolving a fragrance in a liquid carrier, such as ethanol,isopropanol, or some other volatile organic compound. Fragrances mayalso be dissolved in water, although it is often necessary to use asurfactant or other emulsifying agent to dissolve the fragrance inwater. The fragrance evaporates with the carrier, scenting the air.

Solid form fragrances are more desirable for products such asair-freshener used in rooms and automobiles. Diluting the concentratedsolid air freshener at the point of use or at an intermediate locationto form a liquid reduces the cost and space required to transport andstore the air freshener. Thus it can be seen, there is a continuing needfor solid water soluble air fresheners to be diluted by the customer onsite to yield a liquid composition and to provide long lasting fragranceby incorporating as much perfume or fragrance as possible.

It is an object of the present invention to provide a solid airfreshener formulation that is easy to manufacture and does not requirehigh temperature casting.

It is another object of the invention to provide a solid air freshenerformulation that includes greater than 10% fragrance.

It is yet another object of the invention to provide a solid airfreshener that is stable and does not experience significant fragranceweeping across normal transportation temperatures of up to 30-50° C.

It is yet another object of the present invention to provide a solid airfreshener that is easily dissolvable in water, and creates a clearliquid composition that is free of large particles and clumps.

Other objects, aspects and advantages of this invention will be apparentto one skilled in the art in view of the following disclosure, thedrawings, and the appended claims.

SUMMARY OF THE INVENTION

This invention relates to air fresheners, odor masks and malodorneutralizers and, in particular, to a solid air freshener for reductionin transportation costs and for easy spray application upon dissolutionand formation of a liquid composition.

The present invention relates to a solid air freshener and odorneutralizer and the method of manufacturing the improved air freshener.Generally, the air freshener, according to the present invention,comprises a fragrance, a surfactant and a solidifier, the fragrance ispreferably impregnated within a starch substrate or admixed with apowder carrier such as sodium lauryl sulfate. Applicants have identifiedcompositions which can be formed to solids by pressing techniques andwhich can stably include greater than 10% fragrance.

The solid formulations break down easily in the presence of water toform a liquid composition and then may be sprayed within the volume ofair to be freshened. This saves on transportation costs as the solid maybe formulated into the liquid composition at the point of use ratherthan at the manufacturing site.

This invention provides a substantially solid pressed composition forcontrolling odors once diluted into the liquid composition. The solidcomposition includes a fragrance component and preferably a starch orsodium lauryl sulfate carrier in combination with surfactant/solidifiercomponent. The surfactant/solidifier may be the same or differentcompounds. According to the invention the air freshener includes afragrance component of from about 40% by weight to about 80% by weightof the composition and a surfactant/solidifier component which comprisesfrom about 20% by weight to about 60% by weight of the composition. Insome preferred embodiments the surfactant/solidifier is each present ina ratio greater than about 1:1, preferably 5:1. Additional componentsmay include viscosity modifiers, and/or solubility modifiers such asdisintegration or dissolution aids, coupler compounds to bring thefragrance to solution, a high temperature stabilizer, an effervescencedissolution combination, deodorizers, dyes, colorants and the like. Thepresent invention also includes an article of manufacture, the articleof manufacture including the above-referenced substantially solidpressed composition in a container.

The present invention further provides a method of making a solidcomposition by extrusion, pressing or any other means. The method of thepresent invention can produce a stable solid with reduced leaching offragrance without employing a melt and solidification of the melt as inconventional casting. Forming a melt requires the expense of heating acomposition to melt it as well as safety issues of handling a hot melt.In contrast, the present method can employ ambient temperature andhumidity during solidification. The solids of the present invention areheld together not by solidification from a melt but by binding throughcompression.

The present invention also includes a method for deodorizing/fresheninga surface, bounded volume of air, or environment. The method includedissolving the solid pressed air freshener to form a liquid composition,and applying the liquid solution to the surface, bounded volume of air,or environment to eliminate or attenuate odors.

The present invention may further provide a method of applying apredetermined concentration of a deodorizing solution for eliminating orattenuating odors.

Additional objects, advantages, and features of various embodiments ofthis invention will be set forth in part in the description whichfollows, and in part will become apparent to those skilled in the artupon examination of the following, or may be learned by practice of theinvention. The objects and advantages of various embodiments of thisinvention may be realized and attained by means of the instrumentalitiesand combinations particularly pointed out in the appended claims. Thus,these and other objects, features, and advantages of this invention willbecome apparent to a person of ordinary skill in the art from thedescription which follows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the presently described technology will be described in connectionwith one or more preferred embodiments, it will be understood by thoseskilled in the art that the technology is not limited to only thoseparticular embodiments. To the contrary, the presently describedtechnology includes all alternatives, modifications, and equivalents asmay be included within the spirit and scope of the appended claims.

The term “solid” is defined as an essentially homogeneous dispersion,which is nonflowable at room temperature (e.g., 68° F. (20° C.)).Embodiments of the solid of this invention may have a melting point ofat least about 37.7° C. (100° F.), at least about 45° C. (113° F.), orat least about 52° C. (125° F.). A substantially solid composition isone which does not exit a container when the open container is inverted(when the container opening is downwardly oriented). The presentsubstantially solid composition is also distinguished from a compositionwhich, while solid, is powdered, particulate, or granular in that itwill not exit an opened, inverted container as opposed to the formerproducts, which are free-flowing and are not consolidated in onediscrete mass. In one aspect, the present substantially solid pressedproducts are made by pressing dry ingredients and an optional binder ina mold. Subsequently, the present substantially solid composition can bedispensed from within these containers. However, the presentsubstantially solid composition can be removed from the molds afterhardening and then dispensed without the use of these containers aswell.

It should be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the content clearly dictates otherwise. Thus, for example,reference to a composition containing “a compound” includes a mixture oftwo or more compounds. It should also be noted that the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

The term “actives” or “percent actives” or “percent by weight actives”or “actives concentration” are used interchangeably herein and refers tothe concentration of those ingredients involved in cleaning expressed asa percentage minus inert ingredients such as water or salts.

As used herein, “weight percent,” “wt. %,” “percent by weight,” “% byweight,” and variations thereof refer to the concentration of asubstance as the weight of that substance divided by the total weight ofthe composition and multiplied by 100. It is understood that, as usedhere, “percent,” “%,” and the like are intended to be synonymous with“weight percent,” “wt. %,” etc.

The term “about,” as used herein, modifying the quantity of aningredient in the compositions of the invention or employed in themethods of the invention refers to variation in the numerical quantitythat can occur, for example, through typical measuring and liquidhandling procedures used for making concentrates or use solutions;through inadvertent error in these procedures; through differences inthe manufacture, source, or purity of the ingredients employed to makethe compositions or carry out the methods; and the like. The term aboutalso encompasses amounts that differ due to different equilibriumconditions for a composition resulting from a particular initialmixture. Whether or not modified by the term “about,” the claims includeequivalents to the quantities. All numeric values are herein assumed tobe modified by the term “about,” whether or not explicitly indicated.The term “about” generally refers to a range of numbers that one ofskill in the art would consider equivalent to the recited value (i.e.,having the same function or result). In many instances, the terms“about” may include numbers that are rounded to the nearest significantfigure.

The recitation of numerical ranges by endpoints includes all numberssubsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3,3.80, 4, and 5).

Compositions of the Invention

The present substantially solid pressed composition may include: afragrance component, optionally with a starch or surfactant carrier, incombination with a surfactant and solidifier and optional ingredientsto, e.g., modify the viscosity of the composition or modify thesolubility of the use solution, such as disintegration or dissolutionaids, coupler compounds to bring the fragrance into solution, a hightemperature stabilizer, an effervescence dissolution combination, andthe like. The surfactant and solidifier may be the same or differentcompounds. According to the invention a pressed air freshener isdisclosed which includes a fragrance component of from about 40% byweight to about 80% by weight of the composition and the surfactant andsolid air freshening composition comprise from about 20% by weight toabout 60% by weight of the composition.

Fragrance

The present solid air freshening composition includes fragrances, whichare pleasant smelling and which mask objectionable odors. Non-limitingexamples of these fragrances include: Irish Spring™ fragrance(Intercontinental Fragrances), Lemon fragrance (Value Products), 9501Nonacid Bathroom Cleaner Fragrance™ (Intercontinental Fragrances).

The solid pressed air fresheners of the invention can include greaterthan 10% fragrance. These fragrances may be present in amounts, byweight, of between about 10% and 35%, between about 10% and 30%, betweenabout 10% and 25%, or any range subsumed therein. A person of ordinaryskill in the art will appreciate that other suitable fragrances arereadily available and may be utilized in the present invention withoutundue experimentation.

The fragrance and starch carrier are present in the invention in anamount from about 40% by weight to about 80% by weight of the pressedsolid composition.

Surfactant

The solid air freshening composition of the invention can include asurfactant or surfactant system. A variety of surfactants can be used ina solid air freshening compositions, such as anionic, nonionic,cationic, and zwitterionic surfactants. Exemplary surfactants that canbe used are commercially available from a number of sources. For adiscussion of surfactants, see Kirk-Othmer, Encyclopedia of ChemicalTechnology, Third Edition, volume 8, pages 900-912.

Anionic surfactants useful in the solid air freshening compositionincludes, for example, carboxylates such as alkylcarboxylates(carboxylic acid salts) and polyalkoxycarboxylates, alcohol ethoxylatecarboxylates, and the like; sulfonates such as alkylsulfonates,alkylbenzenesulfonates, alkylarylsulfonates, sulfonated fatty acidesters, and the like; sulfates such as sulfated alcohols, sulfatedalcohol ethoxylates, sulfated alkylphenols, alkylsulfates,sulfosuccinates, alkylether sulfates, and the like; and phosphate esterssuch as alkylphosphate esters, and the like. Exemplary anionicsurfactants include sodium alkylarylsulfonate, alpha-olefinsulfonate,and fatty alcohol sulfates.

Nonionic surfactants useful in the solid air freshening compositioninclude, for example, those having a polyalkylene oxide polymer as aportion of the surfactant molecule. Such nonionic surfactants include,for example, chlorine-, benzyl-, methyl-, ethyl-, propyl-, butyl- andother like alkyl-capped polyethylene glycol ethers of fatty alcohols;polyalkylene oxide free nonionics such as alkyl polyglycosides; sorbitanand sucrose esters and their ethoxylates; alkoxylated ethylene diamine;alcohol alkoxylates such as alcohol ethoxylate propoxylates, alcoholpropoxylates, alcohol propoxylate ethoxylate propoxylates, alcoholethoxylate butoxylates, and the like; polyoxyethylene glycol ethers andthe like; carboxylic acid esters such as glycerol esters,polyoxyethylene esters, ethoxylated and glycol esters of fatty acids,and the like; carboxylic amides such as diethanolamine condensates,monoalkanolamine condensates, polyoxyethylene fatty acid amides, and thelike; and polyalkylene oxide block copolymers including an ethyleneoxide/propylene oxide block copolymer such as those commerciallyavailable under the trademark PLURONIC® (BASF-Wyandotte), and the like;and other like nonionic compounds. Silicone surfactants such as theABIL® B8852 can also be used.

Cationic surfactants that can be used in the solid air fresheningcomposition include amines such as primary, secondary and tertiarymonoamines with C₁₋₈ alkyl or alkenyl chains, ethoxylated alkylamines,alkoxylates of ethylenediamine, imidazoles such as a1-(2-hydroxyethyl)-2-imidazoline, a2-alkyl-1-(2-hydroxyethyl)-2-imidazoline, and the like; and quaternaryammonium salts, as for example, alkylquaternary ammonium chloridesurfactants such as n-alkyl(C₁₂-C₁₈)dimethylbenzyl ammonium chloride,n-tetradecyldimethylbenzylammonium chloride monohydrate, anaphthylene-substituted quaternary ammonium chloride such asdimethyl-1-naphthylmethylammonium chloride, and the like. The cationicsurfactant can be used to provide sanitizing properties.

Zwitterionic surfactants that can be used in the solid air fresheningcomposition include betaines, imidazolines, and propinates.

The surfactants are present in the composition in an amount of fromabout 20% by weight to about 50% by weight of the composition.

Solidifier

The composition also includes a solidifier. The solidifier can comprisefrom about 15% by weight to about 40% by weight of the composition. Insome cases the solidifier is also the surfactant. Such as Tomadol® 25-20or Tomadol 25-12® ethoxylated alcohol surfactants or those availablefrom Lambent under the tradename Lumulse™. In this situation, thesurfactant/solidifier is present in the solid composition at amounts offrom about 20% by weight to about 80% by weight of the composition.

Suitable materials used as solidifiers include alkaline polyacrylatesolutions, alkali soluble acrylic copolymer emulsions, PEG-100 stearate,stearamide MEA, paraffin, ozokerite and cetearyl alcohol, cellulosederivatives, polyvinyl methyl ether, polyurethane thickeners,polyethylene oxide, and natural gums (including, Guar Gum, GumArabic,Gum Karaya, alginates, casein). In a preferred embodiment the solidifieris polyethylene glycol. The polyethylene glycol may be substituted atone or both ends as described supra and has an average molecular weightof about 2000 to about 6500 (PEG 2000-PEG 6500), and preferably, has anaverage molecular weight ranging from about 3000 to about 5000. Ingeneral, the number appearing after the designation “PEG” (polyethyleneglycol) indicates the average molecular weight, e.g. PEG 200 representspolyethylene glycol with an average molecular weight of about 200, etc.

Additional Functional Components

Additional functional components may also optionally be incorporatedinto the compositions of the invention and include viscosity modifiers,and/or solubility modifier such as disintegration or dissolution aids,coupler compounds to bring the fragrance to solution, a high temperaturestabilizer, an effervescence dissolution combination, and the like.

Disintegration Aid

These substances, also known as “disintegrants” based on their action,increase their volume when water is added, whereupon first the intrinsicvolume increases (swelling) on the one hand, while on the other hand apressure can be created via the release of gases, causing the solidcomposition to disintegrate into smaller particles. Old familiardisintegration aids include, for example, carbonate/citric acid systems,but other organic acids may also be used. Swelling disintegration aidsinclude, for example, synthetic polymers such as polyvinylpyrrolidone(PVP) or natural polymers and/or modified natural substances such ascellulose and starch and their derivatives, alginates or caseinderivatives. Polyvinyl alcohol may be also be used as a disintegrant forthe constituents of the solid. Disintegration aids, when used in thecomposition typically are present in amounts of 5% to 35 wt. %,preferably 10 to 30 wt. % and more preferably 15 to 25 wt. % of thesolid cast composition.

Effervescent System

In addition, gas-evolving effervescent systems may preferably also beused according to invention. The gas-evolving effervescent system mayconsist of a single substance, which releases a gas on coming in contactwith water. Of these compounds, magnesium peroxide should be mentionedin particular, because it releases oxygen on contact with water.However, preferred effervescent systems consist of at least twocomponents, which react to form a gas, e.g., an alkali metal carbonateand/or bicarbonate and an acidifying agent suitable for releasing carbondioxide from the alkali metal salts in aqueous solution. Examples ofacidifying agents that release carbon dioxide from the alkali salts inaqueous solution include boric acid and alkali metal hydrogen sulfates,alkali metal dihydrogen phosphates and other inorganic salts. However,organic acidifying agents are preferred for use, citric acid being anespecially preferred acidifying agent. Acidifying agents are preferablyused in effervescent systems from the group of organic di-, tri- andoligocarboxylic acids and/or mixtures.

An effervescent system, when used in the composition typically arepresent in amounts of 10% to 40 wt. %, preferably 15 to 35 wt. % andmore preferably 20 to 30 wt. % of the solid east composition.

Coupling Agents

The solid cast composition may include one or more coupling agents forbringing the materials of the composition to solution. Some non-limitingexamples of suitable coupling agents include propylene glycol esters,glycerol esters, polyoxyethylene glycerol esters, polyglycerol esters,sorbitan esters, polyoxyethylene sorbitan esters,polyoxyethylene-polyoxypropylene polymers, sulfonates, dioctyl sodiumsuccinate, stearoyl lactylate, and complex esters such as acetylated,lactylated, citrated, succinhylated, or diacetyl tartarated glycerides.The coupling agent is preferably a sorbitan ester such aspolyoxyethylene (20) sorbitan monooleate, commercially available asPolysorbate 80, polyoxyethylene (20) sorbitan monostearate, commerciallyavailable as Polysorbate 60, and polyoxyethylene (20) sorbitanmonolaurate, commercially available as Polysorbate 20.

A coupling agent may be present in a concentration ranging generallyfrom about 10 wt. % to about 40 wt. %, from about 15 wt. % to about 35wt. %, and from about 20 wt. % to about 305 wt. %.

Temperature Stabilizer

Temperature stabilizers can be included to help prevent weeping of thefragrance at higher temperatures. Suitable temperature stabilizingagents include, for example linear or branched polycarboxylate polymers,especially polyacrylates. Inorganic temperature stabilizers includingalumina, various clays, organo-modified clays, aluminates and silicatesare also suitable. Temperature stabilizers may be present in an amountof from about 0.5 wt. % to about 40 wt. %, from about 1 wt. % to about35 wt. %, and from about 5 wt. % to about 30 wt. %.

Deodorants

Deodorants may be incorporated in to the air freshener composition.These are substances which chemically alter odor producing substances.Non-limiting examples of deodorants include: 1. Bacterial spores, e.g.,Sprozyme BCC™ (Semco Labs), 2. Enzymes, e.g., Vegetable ProteinConcentrate A560™ (Carruba, Inc.), 3. Organic zinc compounds, e.g., Zincricinoleate, e.g., Tegosorb™, (Goldschmidt, AG), Zinc alkyl sulfates,Zinc alkylsulfonates, Zinc alkylarylsulfates, Zinc alkylarylsulfonates,Peroxides, e.g., hydrogen peroxide, Perborates, e.g., sodium perborate,Percarbonates, e.g., sodium percarbonate, Persulfates, e.g., sodiumpersulfate, Organic peroxides, e.g., Benzoyl peroxide, Dicumyl peroxide,and Di (2-tert-2-butyl peroxyisopropyl) benzene, Organic peroxyacids(RCO₃H), e.g., Peroxyformic acid, Peroxyacetic acid, Peroxybenzoic acid,and Metachloroperoxybenzoic acid, Meelium™ (Prentiss Drug and ChemicalCo.), Cationic surfactants, e.g., quaternary ammonium salts, such as,Alkyldimethyl ammonium chloride, Alkyldimethylbenzyl ammonium chloride,and Alkyldimethylethylbenzyl amnonium chloride. These and otherdeodorants may be present in the substantially solid cast composition ofthis invention in an effective amount or in an amount between about0.01% and 90%, between about 0.1% and 40%, between about 0.1% and 20%,between about 1% and 10%, or any range subsumed therein, by weight.

Optional ingredients are also contemplated to be within the scope of thepresent invention. These optional ingredients may include dyes such as(e.g., Pylakor Dark Violet Dye (Pylam Products)), mineral oil, water,alcohols, or glycols.

Methods of Making

In general the air freshener compositions are formed using a batch orcontinuous mixing system. In an exemplary embodiment, a single- ortwin-screw extruder is used to combine and mix one or more componentsagents at high shear to form a homogeneous mixture. In some embodiments,the processing temperature is at or below the melting temperature of thecomponents. The processed mixture may be dispensed from the mixer bypressing, forming, extruding or other suitable means, whereupon thecomposition hardens to a solid form. The structure of the matrix may becharacterized according to its hardness, melting point, materialdistribution, crystal structure, and other like properties according toknown methods in the art. Generally, a solid composition processedaccording to the method of the invention is substantially homogeneouswith regard to the distribution of ingredients throughout its mass andis dimensionally stable.

Specifically, in a forming process, the liquid and solid components areintroduced into the final mixing system and are continuously mixed untilthe components form a substantially homogeneous semi-solid mixture inwhich the components are distributed throughout its mass. In anexemplary embodiment, the components are mixed in the mixing system forat least approximately 5 seconds. The mixture is then discharged fromthe mixing system into, or through, a die, press or other shaping means.The product is then packaged. In an exemplary embodiment, the formedcomposition begins to harden to a solid form in between approximately 1minute and approximately 3 hours. Particularly, the formed compositionbegins to harden to a solid form in between approximately 1 minute andapproximately 2 hours. More particularly, the formed composition beginsto harden to a solid form in between approximately 1 minute andapproximately 20 minutes.

By the term “solid form”, it is meant that the hardened composition willnot flow and will substantially retain its shape under moderate stressor pressure or mere gravity. The degree of hardness of the compositionmay range from that of a fused solid product which is relatively denseand hard, for example, like concrete, to a consistency characterized asbeing a hardened paste. In addition, the term “solid” refers to thestate of the composition under the expected conditions of storage anduse of the solid composition. In general, it is expected that thecomposition will remain in solid form when exposed to temperatures of upto approximately 100° F. and particularly greater than approximately120° F. with no or little leaching of fragrance.

The resulting solid composition may take forms including, but notlimited to: an extruded, molded or formed solid pellet, block, tablet,powder, granule, flake; or the formed solid can thereafter be ground orformed into a powder, granule, or flake. In an exemplary embodiment,extruded pellet materials formed have a weight of between approximately50 grams and approximately 250 grams, extruded solids have a weight ofapproximately 100 grams or greater, and solid blocks formed have a massof between approximately 1 and approximately 10 kilograms. The solidcompositions provide for a stabilized source of functional materials. Ina preferred embodiment, the solid composition may be dissolved, forexample, in an aqueous or other medium, to create a concentrated and/oruse solution. The solution may be directed to a storage reservoir forlater use and/or dilution, or may be applied directly to a point of use.

In other embodiments, the solid air freshener composition is provided inthe form of a multiple-use solid, such as a block or a plurality ofpellets, and can be repeatedly used to generate aqueous compositions formultiple uses, in certain embodiments, the solid air freshenercomposition is provided as a block, or a tablet having a mass of betweenapproximately 5 grams and approximately 10 kilograms. In certainembodiments, a multiple-use form of the solid composition has a massbetween approximately 1 kilogram and approximately 10 kilograms. Infurther embodiments, a multiple-use form of the solid composition has amass of between approximately 5 kilograms and about approximately 8kilograms. In other embodiments, a multiple-use form of the solidcomposition has a mass of between about approximately 5 grams andapproximately 1 kilogram, or between approximately 5 grams andapproximately 500 grams.

The present invention provides a method for deodorizing/freshening asurface, bounded volume of air, or environment. The method may includeproviding the above-described deodorizing solution; and applying thedeodorizing solution to the surface, bounded volume of air, orenvironment to eliminate or attenuate odors therein. In accordance withthe present invention, a method is provided which includes the steps ofapplying water to the solid pressed air freshener so that the airfreshener becomes dissolved to form a liquid composition, typicallywithin a spray bottle, and directing a spray trigger nozzle generally ata surface, bounded volume of air, or environment, and spraying solutionfrom the article.

MORE COMPOSITIONS RANGE PREFERRED PREFERRED Fragrance/carrier 40-80 45-75  50-70  Surfactant 20-50  25-45  30-40  Solidifier 15-40  20-35 25-30  Disintegration aid 0-35 0-30 0-25 Effervescence 0-40 0-35 0-30Coupler 0-40 0-35 0-30 High temp stabilizer 0-40 0-35 0-30

The ratio of surfactant to solidifier is greater than 1:1, preferably1:3 and more preferably 1:5. The surfactant may also be a solidifier.

The present invention will now be further illustrated by way of thefollowing non-limiting examples, in which parts and percentages are byweight unless otherwise indicated.

EXAMPLES

The present invention is more particularly described in the followingexamples that are intended as illustrations only, since numerousmodifications and variations within the scope of the present inventionwill be apparent to those of skill in the art. Unless otherwise noted,all parts, percentages, and ratios reported in the following examplesare on a weight basis, and all reagents used in the examples wereobtained or are available from the chemical suppliers described below ormay be synthesized by conventional techniques.

Materials Used

-   Chemia fragrance/starch powder combination available from Chemia    Corporation, St Louis Mo.-   Chemia fragrance/SLS powder combination available from Chemia    Corporation, St Louis Mo.-   Laundry Fresh fragrance available from Arylessence, Marietta, Ga.-   Lumulse POE-40—C₁₈ 40 moles EO—ethoxylated stearic acid, available    from Lambent Technologies Corporation, Gurnee, Ill.-   Lumulse POE-100—C₁₈ 100 moles EO—ethoxylated stearic acid—available    from Lambent Technologies Corporation, Gurnee, Ill.-   Tomadol 25-12 a nonionic Alcohol Ethoxylate surfactant made from    linear C12-15 alcohol with 11.9 moles (average) of ethylene oxide    available from Air products, Inc., Allentown, Pa.-   Tomadol 25-7 a nonionic Alcohol Ethoxylate surfactant made from    linear C12-15 alcohol with 7.3 moles (average) of ethylene oxide,    available from Air products, Inc., Allentown, Pa.-   Tomadol 25-20 a nonionic Alcohol Ethoxylate surfactant made from    linear C12-15 alcohol with 20 moles (average) of ethylene oxide,    available from Air products, Inc., Allentown, Pa.-   Acusol 445ND a spray dried homopolymer of acrylic acid with a    molecular weight of 4500 available from Dow Chemical Company    Midland, Mich.-   Sipernat 22 a silica with spherical particles, low fines content and    high oil absorption (DBP). Available from The Carey Company,    Addison, Ill.    Formulations

FRAGRANCE/STARCH Chemia fragrance starch powder 40-50 wt. %  Tomadol20-50 wt. %  PEG 0-40 wt. % Sodium bicarbonate/citric acid 0-30 wt. %Sipernat 22 0-20 wt. % Acusol 445ND  0-5 wt. % FRAGRANCE SLS Chemiafragrance SLS 75-85 wt. %  PEG 0-20 wt. % Lumulose (POE 40 or 100) 0-20wt. % Acusol 0-10 wt. % ARYLESSENCE/SLS Arylessence fragrance SLS 40-70wt. %  Polyvinyl pyrrolidone 0-30 wt. % Sipernat 22 0-10 wt. %Sodium/bicarbonate/citric acid 0-30 wt. % Sodium cumene sulfonate 0-25wt. % Accusol 445ND 0-30 wt. %

The formulations were mixed and 50 grams of sample were placed into acylindrical punch assembly. The punch assembly was placed in the centerof the press plates. The press lever was cranked until 1000 psi wasreached and held for 20 seconds. The psi occasionally relaxed to a lowernumber over time, so small adjustments with the lever to reach 1000 psiwere sometimes necessary.

Successful formulations were stable under a range of temperatures,formed a clear use solution upon disintegration, and did not havesignificant fragrance weep.

Starch Technology Examples 1-9

The raw materials identified for each of Example 1-9 in Table 1 belowwere combined and mixed. Each of Examples 1-9 contained Chemiafragrance/starch powder combination mixed with various surfactants,solidifiers, disintegration aids, effervescence components, couplers,and high temp stabilizers.

TABLE A Example Example Example Example Example Example Example ExampleExample 1 2 3 4 5 6 7 8 9 Fragrance/starch 40% 40% 40% 40% 40% 50% 40%40% 40% Tomadol 25-12 10% 10% 10% 10% 20% Tomadol 25-7 10% 10% 10% 10%15% PEG 4000 20% 20% 20% 20% 25% 20% 20% 20% Sodium Sulfate 20% powderSodium 20% Bicarbonate powder PEG 1450 20% Micro 20% CrystallineCellulose powder Tomadol 25-20 50% 40% Lumulse 1820 40% Lumulse POE 40%40

All raw materials unless otherwise specified were mixed to form amixture and then placed into a cylindrical punch assembly. The punchassembly was placed in the center of the press plates. The press leverwas cranked until 1000 psi was reached and held for 20 seconds. The psioccasionally relaxed to a lower number over time, so small adjustmentswith the lever to reach 1000 psi were sometimes necessary.

An oven stability test was conducted in which the solids were placed inan oven at 50° C. for seven days to determine the stability of thesolids. Visual observations of the solids following the storage periodwere recorded.

The solids were also diluted with dilution water to form a use solution.The dilution test investigated whether the use solution havingapproximately 0.3125% by weight fragrance was clear or cloudy.Observations regarding the use solution clarity were recorded. Table Bprovides the oven test results and the dilution test results.

TABLE B Example 1 Reduced surfactant load Sodium Sulfate as filler PEG4000 as solidifying agent PEG 4000 was melted before it was mixed intothe system Formula was the consistency of a stiff cookie dough beforepressing Formula was pressed Formula is resistant to crumbling oncepressed solid is cooled Use solution (0.3125% fragrance) in 5 grainwater is cloudy Example 2 Reduced surfactant load Sodium Bicarbonate asfiller PEG 4000 as solidifying agent PEG 4000 was melted before it wasmixed into the system Formula was the consistency of a stiff cookiedough before pressing Formula was pressed Formula is resistant tocrumbling once pressed solid is cooled Use solution (0.3125% fragrance)in 5 grain water is cloudy Example 3 Reduced surfactant load PEG 1450 asfiller PEG 4000 as solidifying agent PEG 4000 was melted before it wasmixed into the system Formula was the consistency of a stiff cookiedough before pressing Formula was pressed Formula is resistant tocrumbling once pressed solid is cooled Solid was a little wet coming outof the press but did not leak during pressing Use solution (0.3125%fragrance) in 5 grain water is cloudy Example 4 Reduced surfactant loadMicro Crystalline Cellulose as filler PEG 4000 as solidifying agent PEG4000 was melted before it was mixed into the system Formula was theconsistency of wet sand Formula was pressed Formula is resistant tocrumbling once pressed solid is cooled Solid was a little wet coming outof the press but did not leak during the pressing Use solution (0.3125%fragrance) in 5 grain water is cloudy Quite a bit of starch & cellulosesettling at the bottom of the beaker after dilution Example 5 Trying toincrease the surfactant load PEG 4000 as solidifying agent PEG 4000 wasmelted before it was mixed into the system Formula is slightly too softFormula was pressed Pressed solid was sticking to the punch Formula isresistant to crumbling once pressed solid is cooled Use solution(0.3125% fragrance) in 5 grain water is cloudy Example 6 Trying toincrease surfactant load Trying to solidify with a surfactant instead ofPEG Tomadol 25-20 was melted before it was mixed into the system Formulawas pressed Formula is resistant to crumbling once pressed solid iscooled Use solution (0.3125% fragrance) in 5 grain water is cloudyExample 7 Trying to increase surfactant load Trying to solidify with thehelp of a surfactant in addition to PEG Tomadol 25-20 was melted beforeit was mixed into the system PEG 4000 was melted before it was mixedinto the system Formula was pressed Formula is resistant to crumblingonce pressed solid is cooled Use solution (0.3125% fragrance) in 5 grainwater is cloudy Example 8 Trying to increase surfactant load Trying tosolidify with the help of a surfactant in addition to PEG PEG 4000 wasmelted before it was mixed into the system Formula was pressed Pressedsolid is resistant to crumbling Use solution (0.3125% fragrance) in 5grain water is cloudy Example 9 Trying to increase surfactant loadTrying to solidify with the help of a surfactant in addition to PEG PEG4000 was melted before it was mixed into the system Lumulse POE 40 wasmelted before it was mixed into the system Formula was pressed Pressedsolid is waxy looking Pressed solid is resistant to crumbling Usesolution (0.3125% fragrance) in 5 grain water is cloudySLS Technology

The raw materials identified for each of Examples 10-16 in Table C belowwere combined and mixed. Each of Examples 10-16 contained Chemiafragrance/SLS powder combination mixed with various surfactants,solidifiers, disintegration aids, effervescence components, couplers,and high temp stabilizers.

TABLE C Example 10 Example 11 Example 12 Example 13 Example 14 Example15 Example 16 Fragrance/SLS 75% 75% 75% 75% 75% 75% 75% Fragrance  5% 5%  5%  5%  5%  5%  5% PEG 4000 20% 15% PEG 8000 15% Lumulse POE 20% 40Lumulse POE 20% 15% 100 PEG 1450 20% Acusol  5%  5%  5% 445ND powder

All raw materials unless otherwise specified were mixed to form amixture and then placed into a cylindrical punch assembly. The punchassembly was placed in the center of the press plates. The press leverwas cranked until 1000 psi was reached and held for 20 seconds. The psioccasionally relaxed to a lower number over time, so small adjustmentswith the lever to reach 1000 psi were sometimes necessary.

An oven stability test was conducted in which the solids were placed inan oven at 50° C. for seven days to determine the stability of thesolids. Visual observations of the solids following the storage periodwere recorded.

The solids were also diluted with dilution water to form a use solution.The dilution test investigated whether the use solution havingapproximately 0.3125% by weight fragrance was clear or cloudy.Observations regarding the use solution clarity were recorded. Table Dprovides the oven test results and the dilution test results.

TABLE D Example 10 PEG 4000 as solidifying agent PEG 4000 was meltedbefore it was mixed into the system Formula was pressed Ribbons ofmaterial were being extruded from the bottom of the press when pressurewas applied - may not need 1000 psi of pressure Pressed solid isresistant to crumbling Use solution (0.3125% fragrance) in 5 grain wateris clear Placing use solution on stability (40° F. & 100° F.) -solutions are stable Placed pressed solid on stability (120° F.) -weeping observed Example 11 Trying to solidify with Lumulse POE 40Lumulse POE 40 was melted before it was mixed into the system Formulawas pressed Ribbons of material were being extruded from the bottom ofthe press when pressure was applied - may not need 1000 psi of pressurePressed solid is resistant to crumbling Use solution (0.3125% fragrance)in 5 grain water is clear Use solution (0.3125% fragrance ) in 17 grainwater is clear Placing use solution on stability (40° F. & 100° F.) -solutions are stable Placed pressed solid on stability (120° F.) - noweeping observed Example 12 Trying to solidify with Lumulse POE 100Lumulse POE 100 was melted before it was mixed into the system Formulawas pressed Ribbons of material were being extruded from the bottom ofthe press when pressure was applied - may not need 1000 psi of pressurePressed solid is resistant to crumbling Use solution (0.3125% fragrance)in 5 grain water is clear Placing use solution on stability (40° F. &100° F.) - solutions are stable Placed pressed solid on stability (120°F.) - weeping observed Example 13 PEG 1450 as solidifying agent PEG 1450was melted before it was mixed into the system Formula was pressedRibbons of material were being extruded from the bottom of the presswhen pressure was applied - may not need 1000 psi of pressure Pressedsolid is resistant to crumbling Use solution (0.3125% fragrance) in 5grain water is clear Use solution (0.3125% fragrance) in 17 grain wateris clear Placed pressed solid on stability (120° F.) - no weepingobserved Example 14 Modified Example #10 Acusol 445ND was added to seeif it could dry up some of the fragrance seen weeping from the Example#10 solid at high temperature stability (120° F.) PEG 4000 assolidifying agent PEG 4000 was melted before it was mixed into thesystem Formula was pressed Ribbons of material were being extruded fromthe bottom of the press when pressure was applied - may not need 1000psi of pressure Pressed solid is resistant to crumbling Use solution(0.3125% fragrance) in 5 grain water is slightly hazy Placed pressedsolid on stability (120° F.) - weeping observed Example 15 ModifiedExample #12 Acusol 445ND was added to see if it could dry up some of thefragrance seen weeping from the Example #12 solid at high temperaturestability (120° F.) Trying to solidify with Lumulse POE 100 Lumulse POE100 was melted before it was mixed into the system Formula was pressedRibbons of material were being extruded from the bottom of the presswhen pressure was applied - may not need 1000 psi of pressure Pressedsolid is resistant to crumbling Use solution (0.3125% fragrance) in 5grain water is clear Placed pressed solid on stability (120° F.) -weeping observed Example 16 Acusol 445ND was added to see if it coulddry up some of the fragrance seen weeping from the Formula #36 solid athigh temperature stability (120° F.) PEG 8000 as solidifying agent PEG8000 was melted before it was mixed into the system Formula was pressedRibbons of material were being extruded from the bottom of the presswhen pressure was applied - may not need 1000 psi of pressure Pressedsolid is resistant to crumbling Use solution (0.3125% fragrance) in 5grain water is slightly hazy Placed pressed solid on stability (120°F.) - weeping observedWater Soluble Polymer Technology

The raw materials identified for each of Examples 17-18 in Table E belowwere combined and mixed. Each of Examples 17-18 contained fragrance andwater soluble polymers mixed with various surfactants, solidifiers,disintegration aids, effervescence components, couplers, and high tempstabilizers.

TABLE E Example 17 Example 18 SLS powder 20% 20% Fragrance 20% 20%Polyvinyl pyrrolidone powder 30% Poly vinyl alcohol powder 30% PEG 400030% 30%

All raw materials unless otherwise specified were mixed to form amixture and then placed into a cylindrical punch assembly. The punchassembly was placed in the center of the press plates. The press leverwas cranked until 1000 psi was reached and held for 20 seconds. The psioccasionally relaxed to a lower number over time, so small adjustmentswith the lever to reach 1000 psi were sometimes necessary.

An oven stability test was conducted in which the solids were placed inan oven at 50° C. for seven days to determine the stability of thesolids. Visual observations of the solids following the storage periodwere recorded.

The solids were also diluted with dilution water to form a use solution.The dilution test investigated whether the use solution havingapproximately 0.3125% by weight fragrance was clear or cloudy.Observations regarding the use solution clarity were recorded. Table Fprovides the oven test results and the dilution test results.

TABLE F Example 17 PEG 4000 as solidifying agent PEG 4000 was meltedbefore it was mixed into the system Formula was pressed Pressed solid isresistant to crumbling Use solution (0.3125% fragrance) in 5 grain wateris cloudy Example 18 PEG 4000 as solidifying agent PEG 4000 was meltedbefore it was mixed into the system Formula was pressed Pressed solid isresistant to crumbling Use solution (0.3125% fragrance) in 5 grain wateris cloudy This particular PVA is not cold water solubleEffervescent Technology

The raw materials identified for each of Examples 19-21 in Table G belowwere combined and mixed. Each of Examples 19-21 contained fragrance andvarious effervescence components mixed with various surfactants,solidifiers, disintegration aids, couplers, and high temp stabilizers.

TABLE G Example 19 Example 20 Example 21 Fragrance 20% 20% 20% Sipernat22 powder 10% 10% SLS powder 50% 25% 25% Sodium cumene 25% 25% sulfonateSodium bicarbonate 10% 10% 15% powder Citric acid powder 10% 10% 15%

All raw materials unless otherwise specified were mixed to form amixture and then placed into a cylindrical punch assembly. The punchassembly was placed in the center of the press plates. The press leverwas cranked until 1000 psi was reached and held for 20 seconds. The psioccasionally relaxed to a lower number over time, so small adjustmentswith the lever to reach 1000 psi were sometimes necessary.

An oven stability test was conducted in which the solids were placed inan oven at 50° C. for seven days to determine the stability of thesolids. Visual observations of the solids following the storage periodwere recorded.

The solids were also diluted with dilution water to form a use solution.The dilution test investigated whether the use solution havingapproximately 0.3125% by weight fragrance was clear or cloudy.Observations regarding the use solution clarity were recorded. Table Hprovides the oven test results and the dilution test results.

TABLE H Example 19 Formula was pressed Pressed solid is resistant tocrumbling Pressed 30 g at 2500 psi, 2000 psi and 1500 psi for 20 secondsAll tablets were splitting Use solution (0.3125% fragrance) in 5 grainwater is cloudy Sipernat 22 leaves a grit behind in use solution Example20 Formula was pressed Pressed solid is resistant to crumbling Pressed30 g at 1500 psi for 20 seconds Use solution (0.3125% fragrance) in 5grain water is cloudy Sipernate 22 leaves a grit behind in use solutionExample 21 Formula was pressed Pressed solid is resistant to crumblingPressed 30 g at 1500 psi for 20 seconds Use solution (0.3125% fragrance)in 5 grain water is clear Placing solid on stability (120° F.) - noweeping observed Formula was dispense tested - did not dispense enoughat either cold or hot waterOther

The raw materials identified for each of Examples 22-23 in Table I belowwere combined and mixed. Each of Examples 22-23 contained fragrance andvarious surfactants, solidifiers, disintegration aids, effervescencecomponents, couplers, and high temp stabilizers.

TABLE I Example 22 Example 23 Fragrance 20% 20% SLS powder 25% 25%Sodium cumene sulfonate 25% 25% powder Sodium citrate powder 30% Acusol445ND powder 30%

All raw materials unless otherwise specified were mixed to form amixture and then placed into a cylindrical punch assembly. The punchassembly was placed in the center of the press plates. The press leverwas cranked until 1000 psi was reached and held for 20 seconds. The psioccasionally relaxed to a lower number over time, so small adjustmentswith the lever to reach 1000 psi were sometimes necessary.

An oven stability test was conducted in which the solids were placed inan oven at 50° C. for seven days to determine the stability of thesolids. Visual observations of the solids following the storage periodwere recorded.

The solids were also diluted with dilution water to form a use solution.The dilution test investigated whether the use solution havingapproximately 0.3125% by weight fragrance was clear or cloudy.Observations regarding the use solution clarity were recorded. Table Jprovides the oven test results and the dilution test results.

TABLE J Example 22 Formula was pressed Ribbons of material were beingextruded from the bottom of the press when pressure was applied - maynot need 1000 psi of pressure Pressed solid is resistant to crumblingUse solution (0.3125% fragrance) in 5 grain water is clear Placing solidon stability (120° F.) - no weeping observed Formula was dispensetested - did not dispense enough at either cold or hot water Example 23Formula was pressed Pressed solid is resistant to crumbling Use solution(0.3125% fragrance) in 5 grain water is clear Placing solid on stability(120° F.) - no weeping observed

What is claimed is:
 1. A method of making a solid air freshenercomprising the steps of: combining from about 35 to 60 wt. % of a starchbased fragrance component, from about 15-40 wt. % of a solidifier ofpolyethylene glycol, a disintegration aid, and from about 20-50 wt. % ofa surfactant of one or more of polyethylene oxide, a C8 to C24 alcoholwith 20-40 moles ethoxylate, or sodium lauryl sulfate, wherein saidsurfactant and solidifier are in a ratio of greater than 1:1 on apercent weight basis, and compressing said components to form a solidand further produces a stable solid with reduced leaching of fragrance.2. The method of claim 1 wherein said solid is created without employinga melt as in conventional casting.
 3. The method of claim 1 wherein saidsolid is formed from binding through compression.
 4. The method of claim1 wherein said air freshener is stable under a range of temperatures,formed a clear use solution upon disintegration, and did not havesignificant fragrance weep.
 5. A method of deodorizing/freshening asurface, bounded volume of air, or environment comprising, obtaining apressed solid air freshener composition comprising a fragrance componentof from about 40-80 wt. %, a surfactant of from about 20-50 wt. %, and asolidifier of from about 15-40 wt. % wherein, said fragrance componentcomprises up to about 30% by weight of fragrance; dissolving the solidpressed air freshener to form a liquid composition; and applying theliquid composition to the surface, bounded volume of air, or environmentto eliminate or attenuate odors.
 6. The method of claim 5 furthercomprising the applying a predetermined concentration of the liquidcomposition for eliminating or attenuating odors.
 7. The method of claim5 wherein said dissolving is by: applying water to the solid pressed airfreshener so that the air freshener becomes dissolved to form the liquidcomposition.
 8. Then method of claim 7 wherein said dissolving occurswithin a spray bottle.
 9. The method of claim 8 further comprising:directing a spray trigger nozzle generally at the surface, boundedvolume of air, or environment, and spraying the liquid composition fromthe spray bottle.